Inspired by the SPCR review of the NSK2400, I put together an HTPC using the Fusion and it is nearly silent except for the hard drives. I powered it up with no hard drives and it was almost totally inaudible, so I may purchase a single notebook hard drive. Here are some pics and details:
Power supply: Antec Neo HE 550 - this thing is ultra quiet, near-silent...perfect power supply. I tried a Phantom 500, but mine had a high pitched whine and I RMA'd it. NOTE: The Phantom barely fit.
VGA: Gigabyte 7600GT passive cooler (idle: 50C, load: 76C - No match for my X1900XTX, but it also doesn't get to 101C, heat the room and have a fan. One downside: I had to punch out the top of the case to clear the heatpipe.
CPU: A64 X2 3800+ idle: 29C (Cool 'N' Quiet) load: 43C
CPU Cooler: Zalman CNPS-7700Cu modded with a Nexus 120mm fan. Thanks for the idea SPCR! Nexus running slow as possible at 800rpm...any lower and it won't start consistently. Same with the single Nexus case fan.
Mobo/Other cards: Foxconn GeForce 6150K8MA-8EKRS, ATI HDTV Wonder and Creative X-Fi Fatal1ty (all silent!)
Hard drives: Storage/PVR: 500GB (temp: 42-45C)Western Digital SE16 SATA - Even SPCR's reference hard drive is not quiet enough if everything else is silent! Main/Windows: 160GB Maxtor UDMA133 (temp 38-40C) Set at lowest acoustic setting (it's seek noise is quieter than the SE16's). Will replace both with a single notebook hard drive.
I tried running my X1900XTX with Zalman VF-900, but during a 3D game temps shot up to 105C and the ATI protection kicked in.
Always wanted to do a Nexus mod. Wasn't easy as it looked since the stock Zalman fan has some depth, raising it above the heatsink. After cutting out the Nexus and drilling mounting holes, I had to use spacers and longer screws for the blades to clear the heatsink. Hey, my Canon stopped the Nexus fan in its tracks!
Just finished (check out the punched metal to clear the video card's heat pipe):
The 7600GT can drive the Westinghouse 37" monitor pretty well at 1920x1080 for 3D gaming.
Perfect HTPC case
Here's a 1920x1080 screen during stress testing. Link to Full Size image (600k): http://home.comcast.net/~rm19/silentpc/pc_test02.png
Summary: This is the coolest running AND quietest PC I've ever had. Once I get a single notebook hard drive, the LCD buzzing will be all that's left. The PC at idle draws 100 watts and 172 watts at full bore during Battlefield 2 so it's a fairly efficient web/ftp/file/media server as well. Thanks to the SPCR community for all the info and tips.